2nd Gen Non-Engine/Transmission smoke/short from underhood fuse/relay panel

[JBodenhamer]

I was running my truck in the garage this AM and noticed a smoke smell. I lifted the hood and smoke was coming from the black plastic fuse box on the driver's side fender of my 2001 2500. I took off the cover and the right side heavy gauge input wire was very hot and the connection and was melting the plastic of the box. With the cover off, you can see two heavy wires coming into the panel. The left side one goes directly to the driver's side battery. It looks normal and was not melting. There is a fuse called the "alternator bridge" between the contacts which is not blown, and the right side wire that then goes out of the box into the wire loom running to the engine. This one got very hot. The nut fastening it to the metal bus bar in the box is also not real tight now either.



Any ideas on the cause of this? Everything seems normal. Truck starts, no check engine lights, no other obvious problems other than this.



Thanks for the help!



Jon

 

[JBodenhamer]

Figured it out I think. Loose charging wire from the alternator. Increased resistance caused it to get hot. I had thought it might be a bad alternator, but I cleaned everything, cleaned up the melted plastic, and securely tightened the wire onto the mount in the power box, and then started it. Turned on AC full blast, high beam headlights, and radio, and no heat developed, volts stayed right at 13. 9-14 for several minutes.

This is the factory alternator at 11 years and 157K miles, but it appears to be OK.

 

[Allnew2Me]

I'm glad you got it fixed. I seem to remember that there was a TSB regarding the connection at the power distribution panel. Your truck must have missed that one. I had heard about it at the time and checked mine but it was fine. I will however go out and check it again today, thanks for the reminder.

 

[Bob4x4]

SAfety recall B-04... ... ... ... . CBS1B040 is the part# for the repair kit

 

[Bob4x4]

B. Power Distribution Center Stud Repair

NOTE: The following procedure is required if the PDC buss bar, stud and/or

nut for the generator cable require replacement per the inspection in Section

“A. ” Very few vehicles are expected to require this repair.

1. Remove the black generator cable

retaining nut.

2. Lift the black generator cable terminal up

off of the stud.

3. Remove the two fuse retaining screws.

Save the screws for use during

installation.

4. Remove the fuse (Figure 3). Save the

fuse for reinstallation.

5. Carefully pry the buss bar from the PDC

housing. Discard the old buss bar.

6. Slide the generator cable stud out of the PDC housing and discard stud

(Figure 4).

7. Slide the new generator cable stud into the PDC housing.

8. Snap the new bus bar into place.

9. Position the fuse across the battery bus bar and the generator bus bar and install

the retaining screws. Tighten the fuse retaining screws to 30 in. lbs. (3. 5 N⋅m).

10. With the terminal crimp opening facing upward, away from the PDC housing,

place the generator cable terminal over the stud and install the retaining nut

(Figure 3).

11. Tighten the generator cable terminal nut to 80 in. lbs. (9 N⋅m).

Service Procedure (Continued)

Figure 4 – Top View

Safety Recall No. B04 Page 7

 

[JBodenhamer]

Should I be able to go to the dealer and get these parts for free? If so, do I just contact any local dealer?

Thanks,

Jon

 

[Bob4x4]

If your truck is indeed included in the recall they will inspect and repair for free,but not hand out parts. Any dealer can perform the recall. Post the last 9 of your vin I can let you know if it applies to your truck

 

[JBodenhamer]

Bob4x4,

Thanks for the help on this. I left the computer at work over the weekend.

Last 9 of vin are: 01G808364

Thanks,

Jon

 

[Bob4x4]

No recalls are showing up so it looks like you will have to buy the parts and the repair. Sorry

 

[JBodenhamer]

No worries. Thanks for checking, though.